U.S. patent application number 13/554587 was filed with the patent office on 2013-09-12 for image forming apparatus and process cartridge.
This patent application is currently assigned to FUJI XEROX CO., LTD.. The applicant listed for this patent is Shigeto HASHIBA, Kenta IDE, Akihiro KAWASAKI, Kazuhiro KOSEKI, Hirofumi NAKAMURA, Kosuke NARITA, Takahiro SUZUKI. Invention is credited to Shigeto HASHIBA, Kenta IDE, Akihiro KAWASAKI, Kazuhiro KOSEKI, Hirofumi NAKAMURA, Kosuke NARITA, Takahiro SUZUKI.
Application Number | 20130236820 13/554587 |
Document ID | / |
Family ID | 49114409 |
Filed Date | 2013-09-12 |
United States Patent
Application |
20130236820 |
Kind Code |
A1 |
IDE; Kenta ; et al. |
September 12, 2013 |
IMAGE FORMING APPARATUS AND PROCESS CARTRIDGE
Abstract
An image forming apparatus includes at least an
electrophotographic photoreceptor having at least a conductive
support, an undercoat layer, and a photosensitive layer; a charging
device that charges the surface of the electrophotographic
photoreceptor in a contact charging mode, in which only DC voltage
is applied; an electrostatic latent image forming device that
exposes the surface of the charged electrophotographic
photoreceptor to form an electrostatic latent image; a developing
device that develops the electrostatic latent image by a developer
to form a toner image; and a transfer device that directly
transfers the toner image from the electrophotographic
photoreceptor to a transfer medium; and does not include an erasing
device for erasing the surface of the electrophotographic
photoreceptor after the toner image is transferred onto the
transfer medium by the transfer device and before the surface of
the electrophotographic photoreceptor is charged by the charging
device.
Inventors: |
IDE; Kenta; (Kanagawa,
JP) ; NARITA; Kosuke; (Kanagawa, JP) ;
NAKAMURA; Hirofumi; (Kanagawa, JP) ; KOSEKI;
Kazuhiro; (Kanagawa, JP) ; KAWASAKI; Akihiro;
(Kanagawa, JP) ; HASHIBA; Shigeto; (Kanagawa,
JP) ; SUZUKI; Takahiro; (Kanagawa, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IDE; Kenta
NARITA; Kosuke
NAKAMURA; Hirofumi
KOSEKI; Kazuhiro
KAWASAKI; Akihiro
HASHIBA; Shigeto
SUZUKI; Takahiro |
Kanagawa
Kanagawa
Kanagawa
Kanagawa
Kanagawa
Kanagawa
Kanagawa |
|
JP
JP
JP
JP
JP
JP
JP |
|
|
Assignee: |
FUJI XEROX CO., LTD.
Tokyo
JP
|
Family ID: |
49114409 |
Appl. No.: |
13/554587 |
Filed: |
July 20, 2012 |
Current U.S.
Class: |
430/56 ; 399/111;
399/159 |
Current CPC
Class: |
G03G 5/0539 20130101;
G03G 15/75 20130101; G03G 5/14756 20130101; G03G 5/0696 20130101;
G03G 5/14708 20130101; G03G 5/142 20130101; G03G 21/06 20130101;
G03G 5/0542 20130101; G03G 5/0564 20130101; G03G 5/0614 20130101;
G03G 5/144 20130101 |
Class at
Publication: |
430/56 ; 399/111;
399/159 |
International
Class: |
G03G 15/00 20060101
G03G015/00; G03G 21/18 20060101 G03G021/18 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 7, 2012 |
JP |
2012-050622 |
Claims
1. An image forming apparatus, which comprises at least: an
electrophotographic photoreceptor having at least a conductive
support, an undercoat layer provided on the conductive support,
containing metal oxide particles and an electron accepting compound
having an anthraquinone structure with an amount of the electron
accepting compound being from 1 part by weight to 5 parts by weight
with respect to 100 parts by weight of the metal oxide particles,
and having a volume resistivity, as measured by an AC impedance
method, in the range of 3.5.times.10.sup.8 .OMEGA.m to
1.0.times.10.sup.9 .OMEGA.m, and a photosensitive layer provided on
the undercoat layer; a charging device that charges the surface of
the electrophotographic photoreceptor in a contact charging mode,
in which only DC voltage is applied; an electrostatic latent image
forming device that exposes the surface of the charged
electrophotographic photoreceptor to form an electrostatic latent
image; a developing device that develops the electrostatic latent
image by a developer to form a toner image; and a transfer device
that directly transfers the toner age from the electrophotographic
photoreceptor to a transfer medium; and which does not comprise an
erasing device for erasing the surface of the electrophotographic
photoreceptor after the toner image is transferred onto the
transfer medium by the transfer device and before the surface of
the electrophotographic photoreceptor is charged by the charging
device.
2. The image forming apparatus according to claim 1, wherein the
electron accepting compound is contained in an amount of 2 parts by
weight to 4 parts by weight with respect to 100 parts by weight of
the metal oxide particles.
3. The image forming apparatus according to claim 1, wherein the
electron accepting compound is an electron accepting compound
represented by the following formula (I): ##STR00002## wherein
R.sup.1 and R.sup.2 each independently represent a hydroxyl group,
a methyl group, a methoxymethyl group, a phenyl group, or an amino
group, and m and n each independently represent an integer of 0 to
4.
4. The image forming apparatus according to claim 3, wherein in the
electron accepting compound represented by the formula (I), R.sup.1
is a hydroxyl group, m is from 1 to 3, and n is 0.
5. The image forming apparatus according to claim 1, wherein the
electron accepting compound is an electron accepting compound
having a hydroxyanthraquinone structure.
6. The image forming apparatus according to claim 1, wherein the
metal oxide particles are surface-treated with a silane coupling
agent.
7. The image forming apparatus according to claim 1, wherein the
metal oxide particles are surface-treated with a silane coupling
agent having an amino group.
8. The image forming apparatus according to claim 1, wherein an
amount of the surface treatment agent attached on the surface of
100 parts by weight of the metal oxide particles is from 0.5 part
by weight to 3 parts by weight.
9. The image forming apparatus according to claim 1, wherein the
volume resistivity of the undercoat layer is from
4.0.times.10.sup.8 .OMEGA.m to 9.5.times.10.sup.8 .OMEGA.m in the
measurement by an AC impedance method.
10. The image forming apparatus according to claim 1, wherein the
volume resistivity of the undercoat layer is from
4.5.times.10.sup.8 .OMEGA.m to 9.0.times.10.sup.8 .OMEGA.m in the
measurement by an AC impedance method.
11. A process cartridge, which comprises at least: an
electrophotographic photoreceptor having at least a conductive
support, an undercoat layer provided on the conductive support,
containing metal oxide particles and an electron accepting compound
having an anthraquinone structure with an amount of the electron
accepting compound being from 1 part by weight to 5 parts by weight
with respect to 100 parts by weight of the metal oxide particles,
and having a volume resistivity, as measured by an AC impedance
method, in the range of 3.5.times.10.sup.8 .OMEGA.m to
1.0.times.10.sup.9 .OMEGA.m, and a photosensitive layer provided on
the undercoat layer; and a charging device that charges the surface
of the electrophotographic photoreceptor in a contact charging mode
in which only DC voltage is applied; and which does not comprise an
erasing device for erasing the surface of the electrophotographic
photoreceptor after the toner image formed on the surface of the
electrophotographic photoreceptor is transferred onto the transfer
medium by the transfer device and before the surface of the
electrophotographic photoreceptor is charged by the charging
device; and which is detachable from the image forming
apparatus.
12. The process cartridge according to claim 11, wherein the
electron accepting compound is contained in an amount of 2 parts by
weight to 4 parts by weight with respect to 100 parts by weight of
the metal oxide particles.
13. The process cartridge according to claim 11, wherein the
electron accepting compound is an electron accepting compound
represented by the following formula (1): ##STR00003## wherein
R.sup.1 and R.sup.2 each independently represent a hydroxyl group,
a methyl group, a methoxymethyl group, a phenyl group, or an amino
group, and m and n each independently represent an integer of 0 to
4.
14. The process cartridge according to claim 13, wherein in the
electron accepting compound represented by the formula (1), R.sup.1
is a hydroxyl group, m is from 1 to 3, and n is 0.
15. The process cartridge according to claim 11, wherein the
electron accepting compound is an electron accepting compound
having a hydroxyanthraquinone structure.
16. The process cartridge according to claim 11, wherein the metal
oxide particles are surface-treated with a silane coupling
agent.
17. The process cartridge according to claim 11, wherein the metal
oxide particles are surface-treated with a silane coupling agent
having an amino group.
18. The process cartridge according to claim 11, wherein an amount
of the surface treatment agent attached on the surface of 100 parts
by weight of the metal oxide particles is from 0.5 parts by weight
to 3 parts by weight.
19. The process cartridge according to claim 11, wherein the volume
resistivity of the undercoat layer is from 4.0.times.10.sup.8
.OMEGA.m to 9.5.times.10.sup.8 .OMEGA.m in the measurement by an AC
impedance method.
20. The process cartridge according to claim 11, wherein the volume
resistivity of the undercoat layer is from 4.5.times.10.sup.8
.OMEGA.m to 9.0.times.10.sup.8 .OMEGA.m in the measurement by an AC
impedance method.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority under 35
USC 119 from Japanese Patent Application No. 2012-050622 filed Mar.
7, 2012.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to an image forming apparatus
and a process cartridge.
[0004] 2. Related Art
[0005] Image formation in an electrophotographic mode has been
recently used in a wide range of image forming apparatuses such as
copying machines and laser printers.
SUMMARY
[0006] According to an aspect of the invention, there is provided
an image forming apparatus, which includes at least an
electrophotographic photoreceptor having at least a conductive
support, an undercoat layer provided on the conductive support,
containing metal oxide particles and an electron accepting compound
having an anthraquinone structure with the amount of the electron
accepting compound being from 1 part by weight to 5 parts by weight
with respect to 100 parts by weight of the metal oxide particles,
and having a volume resistivity, as measured by an AC impedance
method, in the range of 3.5.times.10.sup.8 .OMEGA.m to
1.0.times.10.sup.9 .OMEGA.m, and a photosensitive layer provided on
the undercoat layer; a charging unit that charges the surface of
the electrophotographic photoreceptor in a contact charging mode in
which only DC voltage is applied; an electrostatic latent image
forming unit that exposes the surface of the charged
electrophotographic photoreceptor to form an electrostatic latent
image; a developing unit that develops the electrostatic latent
image by a developer to form a toner image; and a transfer unit
that directly transfers the toner image from the
electrophotographic photoreceptor to a transfer medium; and which
does not include an erasing unit for erasing the surface of the
electrophotographic photoreceptor after the toner image is
transferred onto the transfer medium by the transfer unit and
before the surface of the electrophotographic photoreceptor is
charged by the charging unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Exemplary embodiments of the present invention will be
described in detail based on the following figures, wherein:
[0008] FIG. 1 is a schematic diagram showing a cross-section of a
part of the electrophotographic photoreceptor according to the
present exemplary embodiment;
[0009] FIG. 2 is a schematic diagram showing a basic configuration
of the image forming apparatus according to the present exemplary
embodiment;
[0010] FIG. 3 is a schematic diagram showing a basic configuration
of an example of the process cartridge according to the present
exemplary embodiment; and
[0011] FIG. 4 is a mimetic diagram showing an image formed by the
evaluation of Examples.
DETAILED DESCRIPTION
[0012] Hereinbelow, exemplary embodiments will be described in
detail. Further, in the drawings, the same or equivalent elements
have the same symbols attached and duplicate explanation may be
omitted in some cases.
[0013] Image Forming Apparatus
[0014] The image forming apparatus according to the present
exemplary embodiment includes an electrophotographic photoreceptor;
a charging unit that charges the surface of the electrophotographic
photoreceptor; an electrostatic latent image forming unit that
exposes the surface of the charged electrophotographic
photoreceptor to form an electrostatic latent image; a developing
unit that develops the electrostatic latent image by a developer to
form a toner image; and a transfer unit that transfers the toner
image onto a transfer medium.
[0015] For an image forming apparatus having no erasing unit for
erasing the surface of the electrophotographic photoreceptor after
the toner image formed on the surface of the electrophotographic
photoreceptor is transferred onto a transfer body by a transfer
unit and before the surface of the electrophotographic
photoreceptor is charged by the charging unit (which will be
hereinafter referred to as an erase-less system), a charging unit
in a contact charging mode, in which only DC voltage is applied, is
employed as the charging unit and a transfer unit in a direct
transfer mode, which directly transfers the toner image from the
electrophotographic photoreceptor to the transfer medium, is
employed as the transfer unit.
[0016] In addition, for the image forming apparatus configured as
above, an electrophotographic photoreceptor having at least an
undercoat layer containing metal oxide particles and an electron
accepting compound having an anthraquinone structure with an amount
of the electron accepting compound being from 1 part by weight to 5
parts by weight with respect to 100 parts by weight of the metal
oxide particles, and having a volume resistivity, as measured by an
AC impedance method, in the range of 3.5.times.10.sup.8 .OMEGA.m to
1.0.times.10.sup.9 .OMEGA.m; and a photosensitive layer, is
employed as the electrophotographic photoreceptor on the conductive
support.
[0017] Herein, the erase-less systems in the related art remove the
surface potential difference between the exposure portion and the
non-exposure portion of the electrophotographic photoreceptor by
reverse voltage (reverse bias) imparted by the transfer unit that
transfers the toner image from the electrophotographic
photoreceptor.
[0018] However, for the purpose of coping with the demand for a
smaller size and a higher speed, in an erase-less system employing
a contact charging mode in which only a DC voltage is applied and a
direct transfer mode, the surface potential difference between the
exposure portion and the non-exposure portion of the
electrophotographic photoreceptor tends to be hardly removed,
leading to generation of image density unevenness in some
cases.
[0019] It is thought that the reason therefor is as follows. Since
in the direct transfer mode, the resistance value of a transfer
medium (for example, a recording medium such as paper) is high, the
reverse voltage (reverse bias) imparted to the electrophotographic
photoreceptor becomes low by a transfer unit. In addition, in the
contact charging mode in which only a DC voltage is applied, the
surface potential difference between the exposure portion and the
non-exposure portion of the electrophotographic photoreceptor is
not removed.
[0020] Accordingly, in the erase-less system employing a contact
charging mode in which only a DC voltage is applied and a direct
transfer mode in the image forming apparatus according to the
present exemplary embodiment, when the electrophotographic
photoreceptor is configured as above, generation of density
unevenness due to the surface potential difference between the
exposure portion and the non-exposure portion of the
electrophotographic photoreceptor is suppressed.
[0021] The reason therefor is not clear, but is presumed as
follows.
[0022] It is thought that when the volume resistivity of the
undercoat layer of the electrophotographic photoreceptor is
adjusted to a low range of 3.5.times.10.sup.8 .OMEGA.m to
1.0.times.10.sup.9 .OMEGA.m and the resistance value itself of the
undercoat layer is decreased, the resistance of the
electrophotographic photoreceptor is lowered, and although the
reverse voltage (reverse bias) imparted to the electrophotographic
photoreceptor is low, the charges easily flow in the photosensitive
layer.
[0023] It is also thought that when the volume resistivity of the
undercoat layer of the electrophotographic photoreceptor is lowered
and an electron accepting compound having an anthraquinone
structure is then incorporated into the undercoat layer of the
electrophotographic photoreceptor in a large amount of 1 part by
weight to 5 parts by weight with respect to 100 parts by weight of
the metal oxide particles, the charge injection occurring between
the undercoat layer and a photosensitive layer (a single-layered
photosensitive layer having a charge generating/charge transporting
function or a charge generating layer in the function-separated
photosensitive layer) disposed in contact with the undercoat layer
is carried out without intervention (which means that the charge
injection is readily conducted), and as a result, even though the
reverse voltage (reverse bias) imparted to the electrophotographic
photoreceptor is lowered, removal of the surface potential
difference between the exposure portion and the non-exposure
portion of the electrophotographic photoreceptor is attained.
[0024] Therefore, it is thought that in the erase-less system
employing a contact charging mode in which only a DC voltage is
applied and a direct transfer mode in the image forming apparatus
according to the present exemplary embodiment, when the
electrophotographic photoreceptor is configured as above,
generation of density unevenness due to the surface potential
difference between the exposure portion and the non-exposure
portion of the electrophotographic photoreceptor is suppressed.
[0025] Moreover, in the image forming apparatus according to the
present exemplary embodiment, when an electron accepting compound
having a hydroxyanthraquinone structure is employed as the electron
accepting compound having an anthraquinone structure, generation of
density unevenness due to the surface potential difference between
the exposure portion and the non-exposure portion of the
electrophotographic photoreceptor is further suppressed.
[0026] Hereinbelow, the image forming apparatus according to the
present exemplary embodiment will be described in detail with
respect to the respective members.
[0027] [Electrophotographic Photoreceptor]
[0028] FIG. 1 schematically shows the cross-section of a part of
the electrophotographic photoreceptor according to the present
exemplary embodiment. The electrophotographic photoreceptor 1 shown
in FIG. 1 includes, for example, a function-separated
photosensitive layer 3 in which a charge generating layer 5 and a
charge transporting layer 6 are provided separately, and has a
structure in which an undercoat layer 4, the charge generating
layer 5, and the charge transporting layer 6 are laminated on the
conductive support 2 in this order.
[0029] Further, in the present specification, the insulating
property means that the volume resistivity is in the range of equal
to or more than 10.sup.12 .OMEGA.cm, while the conductivity means
that the volume resistivity is in the range equal to or less than
10.sup.1.degree. .OMEGA.cm.
[0030] Hereinbelow, the respective elements of the
electrophotographic photoreceptor 1 will be described.
[0031] Conductive Support
[0032] As the conductive support 2, any one used in the related art
may be used. Examples of the conductive support include metals such
aluminum, nickel, chromium, and stainless steel, plastic films
having thin films of, for example, aluminum, titanium, nickel,
chromium, stainless steel, gold, vanadium, tin oxide, indium oxide,
or ITO, and paper or plastic films coated or impregnated with a
conductivity imparting agent.
[0033] The shape of the conductive support 2 is not restricted to a
drum form and may be a sheet shape or a plate shape.
[0034] When a metal pipe is used as the conductive support 2, its
surface may be in an untreated state or may be subjected to a
treatment such as mirror surface cutting, etching, anodic
oxidation, rough cutting, centerless grinding, sandblasting, and
wet honing in advance.
[0035] Undercoat Layer
[0036] The undercoat layer 4 may contain at least metal oxide
particles and a specific electron accepting compound, and if
necessary, other materials.
[0037] Examples of the undercoat layer 4 include ones formed by
dispersing metal oxide particles and a specific electron accepting
compound in a binder resin.
[0038] Metal Oxide Particles
[0039] Examples of the metal oxide particles include particles of,
for example, zinc oxide, titanium oxide, tin oxide, or zirconium
oxide, and these may be used as a mixture of two or more kinds
thereof.
[0040] The volume average particle diameter of the metal oxide
particles may be, for example, from 50 nm to 200 nm, preferably
from 60 nm to 180 nm, and more preferably from 70 nm to 120 cm.
[0041] Further, the volume average particle diameter of the metal
oxide particles is measured by using, for example, a laser
diffraction particle size distribution measurement device (LA-700:
manufactured by HORIBA, Ltd.). As the measurement method, a sample
in the state of a dispersion is prepared to give a solid content of
2 g, and ion exchange water is added thereto to adjust the amount
of the solution to 40 ml. The solution is then charged into the
cell until an appropriate concentration is given, and after waiting
for 2 minutes, the measurement is carried out. The obtained volume
average particle diameter for each obtained channel is cumulated
from the side of the smaller volume average particle diameter, and
the 50% cumulative volume average particle diameter is defined as
the volume average particle diameter.
[0042] The content of the metal oxide particles included in the
undercoat layer 4 may be, for example, in the range equal to or
more than 2.5% by weight, preferably in the range of 10% by weight
to 70% by weight, and more preferably in the range of 30% by weight
to 50% by weight, with respect to the total amount of the undercoat
layer.
[0043] The metal oxide particles may be subjected to a surface
treatment with a coupling agent having an amino group. The metal
oxide particles may be subjected to a surface treatment with a
coupling agent other than a coupling agent having an amino
group.
[0044] Examples of the coupling agent having an amino group include
a silane coupling agent, a titanate-based coupling agent, an
aluminum-based coupling agent, and a surfactant. Particularly, the
surface treating agent for suppressing fog by adjusting the
resistance, may be, for example, a silane coupling agent.
[0045] The silane coupling agent is an organic silane compound
(organic compound containing a silicon atom), and specific examples
thereof include .gamma.-aminopropyltriethoxysilane,
N,N-bis(.beta.-hydroxyethyl)-.gamma.-aminopropyltriethoxysilane,
N-2-(aminoethyl)-3-aminopropyltrimethoxysilane,
N-2-(aminoethyl)-3-aminopropylmethyldimethoxysilane, and
N-phenyl-3-aminopropyltrimethoxysilane.
[0046] Whether the metal oxide particles are surface-treated with a
coupling agent having an amino group or not is confirmed by
molecular structure analysis by means of, for example, FT-IR, Raman
spectroscopy, or XPS.
[0047] The method for surface treatment of the metal oxide
particles is not particularly limited, but examples thereof include
a dry method and a wet method.
[0048] In the case of carrying out the surface treatment by the dry
method, for example, while stirring metal oxide particles with, for
example, a mixer having a high shear force, a direct surface
treatment agent is added dropwise or a surface treatment agent
dissolved in an organic solvent is added dropwise, and sprayed
together with dry air or nitrogen gas. Dropwise addition or
spraying is carried out, for example, at a temperature equal to or
lower than the boiling point of a solvent. After dropwise addition
or spraying, the solution may be further heated to a temperature
equal to or higher than 100.degree. C. for printing.
[0049] For the wet method, for example, metal oxide particles are
stirred in a solvent and dispersed using, for example, ultrasonic
waves, a sand mill, an attritor, or a ball mill, and a surface
treatment agent solution is added thereto, and stirred or dispersed
therein, and then, the solvent is removed. Examples of the method
for removing the solvent include filtration and distillation. After
removing the solvent, printing may also be carried out at a
temperature equal to or higher than 100.degree. C. In the wet
method, moisture content of the metal oxide particles may be
removed before the addition of a surface treatment agent, and
examples of such a method include a method in which the moisture
content of the metal oxide particles is removed by stirring and
heating in a solvent used for a surface treatment agent solution
and a method in which the moisture content of the metal oxide
particles is removed while subjecting it to azeotropy with a
solvent.
[0050] The amount of the surface treatment agent attached on the
surface (which may be hereinafter referred to as "a surface
treatment amount" in some cases) with respect to 100 parts by
weight of the metal oxide particles may be, for example, from 0.5
part by weight to 3 parts by weight, preferably from 0.5 part by
weight to 2.0 parts by weight, and more preferably from 0.75 part
by weight to 1.30 parts by weight.
[0051] Examples of the method for measuring the surface treatment
amount (that is, amount of the surface treatment agent attached on
the metal oxide particles) include methods for molecular structure
analysis by means of, for example, FT-IR, Raman spectroscopy, or
XPS.
[0052] Electron Accepting Compound
[0053] The electron accepting compound is an electron accepting
compound having an anthraquinone structure. Herein, "the compound
having an anthraquinone structure" is specifically at least one
selected from anthraquinone and anthraquinone derivatives, and more
specifically the electron accepting compound may be a compound
represented by the following formula (1).
##STR00001##
[0054] In the formula (I), R.sup.1 and R.sup.2 each independently
represent a hydroxyl group, a methyl group, a methoxymethyl group,
a phenyl group, or an amino group, and m and n each independently
represent an integer of 0 to 4.
[0055] Further, the compound of the formula (I), in which m and n
are both 0, is anthraquinone, and the compound of the formula (I),
in which at least one of m and in is an integer of 1 to 4, is an
anthraquinone derivative. That is, the anthraquinone derivatives
mean anthraquinone compounds wherein at least one of hydrogen atoms
contained in the anthraquinone is substituted by a substituent such
as a hydroxyl group, a methyl group, methoxymethyl group, a phenyl
group, and an amino group.
[0056] Particularly, among the above compounds, suitable examples
of the electron accepting compound include anthraquinone of the
formula (I), wherein m and n are both 0, and hydroxyanthraquinone
of the formula (I), wherein R.sup.1 is a hydroxyl group, m is from
1 to 3, and in is 0.
[0057] Specific examples of the electron accepting compound include
anthraquinone, purpurin, alizarin, quinizarin, ethyl anthraquinone,
and aminohydroxyanthraquinone.
[0058] Whether the undercoat layer 4 contains an electron accepting
compound having an anthraquinone structure is confirmed by an
analysis method such as gas chromatography, liquid chromatography,
FT-IR, Raman spectroscopy, and XPS.
[0059] The content of the electron accepting compound contained in
the undercoat layer 4 is from 1 part by weight to 5 parts by
weight, and preferably from 2 parts by weight to 4 parts by weight,
with respect to 100 parts by weight of the metal oxide particles
contained in the undercoat layer 4.
[0060] The content ratio of the metal oxide particles and the
electron accepting compound contained in the undercoat layer 4 of
the electrophotographic photoreceptor is confirmed by an analysis
method such as an NMR spectrum, XPS, atomic absorption
spectrometry, and electron beam micro-analyzer.
[0061] Binder Resin
[0062] As the binder resin contained in the undercoat layer 4,
polymeric compounds, such as acetal resins such as a polyvinyl
butyral resin, polyvinyl alcohol resins, casein, polyamide resins,
cellulose resins, gelatin, polyurethane resins, polyester resins,
methacrylic resins, acrylic resins, polyvinyl chloride resins,
polyvinyl acetate resins, vinyl chloride-vinyl acetate-maleic
anhydride resins, silicone resins, silicone-alkyd resins, phenolic
resins, phenol-formaldehyde resins, melamine resins, and urethane
resins, charge transporting resins having charge transporting
groups, or conductive resins such as a polyaniline resin are
used.
[0063] The content of the binder resin contained in the undercoat
layer may be, for example, in the range of 5% by weight to 60% by
weight, preferably from 10% by weight to 55% by weight, and more
preferably from 30% by weight to 50% by weight, with respect to the
total amount of the undercoat layer.
[0064] Other Additives
[0065] Resin particles may be added to the undercoat layer 4 so as
to adjust the surface roughness thereof. Examples thereof include
silicone resin particles and crosslinking PMMA resin particles.
[0066] Further, the surface of the undercoat layer 4 may be
subjected to grinding so as to adjust the surface roughness
thereof. Examples of the grinding method include buffing grinding,
sandblasting treatment, wet honing, and grinding treatments.
[0067] Furthermore, a curing agent or a curing catalyst may be
added to the undercoat layer 4. When the curing agent or the curing
catalyst are added, a curing reaction is sufficiently performed,
and thus, unnecessary elution from the undercoat layer 4 is
suppressed, and increase in the residual potential or decrease in
the sensitivity is suppressed.
[0068] Examples of the curing agent include blocked isocyanate
compounds and melamine resins, and blocked isocyanate compounds are
suitably used. Since blocked isocyanate compounds have isocyanate
groups masked with blocking agents, gelling and thickening of the
coating liquid are suppressed over time, and accordingly, the
working properties are excellent.
[0069] Examples of the curing catalyst include known materials that
are generally used, and the curing catalyst is preferably selected
from acid catalysts, amine-based catalysts, and metal
compound-based catalysts. Further, when a melamine resin is used as
the curing agent, an acid catalyst is preferably used; and when a
blocked isocyanate compound is used, an amine-based catalyst or
metal compound-based catalyst is preferably used. Examples of the
metal compound-based catalyst include stannous oxide, dioctyl tin
dilaurate, dibutyl tin dilaurate, dibutyl tin diacetate, zinc
naphthenate, antimony trichloride, potassium oleate, sodium
O-phenylphenate, bismuth nitrate, ferric chloride, tetra-n-butyl
tin, tetra(2-ethylhexyl)titanate, cobalt 2-ethylhexoate, and ferric
2-ethylhexoate.
[0070] The addition amount of the curing catalyst is preferably
from 0.0001% by weight to 0.1% by weight, and more preferably from
0.001% by weight to 0.01% by weight, with respect to the amount of
the curing agent.
[0071] Formation of Undercoat Layer
[0072] When the undercoat layer 4 is formed, a coating liquid
formed by adding the above-described components to a solvent
(coating liquid for forming an undercoat layer) is used.
[0073] Examples of the solvent include organic solvents, and
specifically, aromatic hydrocarbon-based solvents such as toluene
and chlorobenzene; aliphatic alcohol-based solvents such as
methanol, ethanol, n-propanol, iso-propanol, and n-butanol;
ketone-based solvents such as acetone, cyclohexanone, and
2-butanone; halogenated aliphatic hydrocarbon solvents such as
methylene chloride, chloroform, and ethylene chloride; cyclic or
linear ether-based solvents such as tetrahydrofuran, dioxane,
ethylene glycol, and diethyl ether; and ester-based solvents such
as methyl acetate, ethyl acetate, and n-butyl acetate. These
solvents may be used singly or in combination of two or more kinds
thereof, and are not particularly limited, but a solvent for
dissolving the binder resin is preferably used.
[0074] The amount of the solvent used in the coating liquid for
forming an undercoat layer is not particularly limited as long as
the binder resin is dissolved therein, but it may be, for example,
from 0.05 part by weight to 200 parts by weight, with respect to 1
part by weight of the binder resin.
[0075] Further, for a method for dispersing the metal oxide
particles in a coating liquid for forming an undercoat layer, media
dispersers such as a ball mill, a vibration ball mill, an attritor,
and a sand mill, and medialess dispersers such as a stirrer, an
ultrasonic disperser, a roll mill, and a high-pressure homogenizer
may be used. Further, examples of the high-pressure homogenizer
include a collision-type homogenizer in which a dispersion is
dispersed by liquid-liquid collision, and liquid-wall collision
under high pressure, and a passing-through-type homogenizer in
which a dispersion is dispersed by passing the dispersion through
thin flow paths under high pressure.
[0076] An appropriate dispersing method is preferably chosen so as
to adjust the volume resistivity of the obtained undercoat layer 4
to the range as defined later, and specifically, a sand mill using
glass beads, a ball mill, or the like is preferably used for the
dispersion. The particle diameter of the glass beads is controlled
according to the components such as metal oxide particles and
binder resins to be used, and specifically the particle diameter
may be from 0.1 mm to 10 mm.
[0077] Examples of the method of coating the coating liquid for
forming an undercoat layer on the conductive support 2 include a
dip coating method, an extrusion coating method, a wire bar coating
method, a spray coating method, a blade coating method, a knife
coating method, and a curtain coating method.
[0078] After coating the coating liquid for forming an undercoat
layer on the conductive support 2, heating for drying or curing is
preferably carried out. The curing temperature and the heating time
in the case of using a curing agent or a curing catalyst are
preferably adjusted depending on the kind of the curing agent or
the curing catalyst to be used, and specifically, the heating may
be carried out, for example, at a temperature of 160.degree. C. to
200.degree. C. for 15 minutes to 40 minutes.
[0079] Physical Properties of Undercoat Layer
[0080] The thickness of the undercoat layer 4 is equal to or more
than 10 and more preferably from 15 .mu.m to 40 .mu.l.
[0081] The volume resistivity of the undercoat layer 4 is in the
range of 3.5.times.10.sup.8 .OMEGA.m to 1.0.times.10.sup.9
.OMEGA.m, preferably in the range of 4.0.times.10.sup.8 .OMEGA.m to
9.5.times.10.sup.8 .OMEGA.m, and more preferably in the range of
4.5.times.10.sup.8 .OMEGA.m to 9.0.times.10.sup.8 .OMEGA.m, in the
measurement using an AC impedance method.
[0082] The detailed method for measuring the volume resistivity of
the undercoat layer 4 is as follows.
[0083] First, the impedance of the undercoat layer 4 is measured.
In a sample for impedance measurement, the conductive support such
as an aluminum pipe is used as a cathode, a gold electrode is used
as an anode, an AC voltage with 1 Vp-p is applied from the
high-frequency side in the frequency range of 1 MHz to 1 mHz, and
the AC impedance of each sample is measured. By fitting a graph
with the Cole-Cole plot obtained in the measurement to the
equivalent circuit of parallel RC, the volume resistivity of the
undercoat layer 4 is obtained.
[0084] Further, the method for preparing an undercoat layer sample
for measuring the volume resistivity from an electrophotographic
photoreceptor is as follows.
[0085] For example, coating films such as a charge generating layer
and a charge transporting layer, which coat the undercoat layer,
are removed using a solvent such as acetone, tetrahydrofuran,
methanol, and ethanol, and the gold electrode is mounted by a
vacuum deposition method or a sputtering method on the exposed
undercoat layer to provide an undercoat layer sample for measuring
the volume resistivity.
[0086] Examples of the method for adjusting the volume resistivity
of the undercoat layer 4 within the above ranges include a method
for adjusting the addition amount or the particle diameter of the
metal oxide particles, and a method for modifying the method for
dispersing the metal oxide particles in the coating liquid for
forming an undercoat layer.
[0087] As the particle diameter of the metal oxide particles is
increased, the volume resistivity of the undercoat layer 4 tends to
decrease. Further, by increasing the addition amount of the metal
oxide particles, the volume resistivity of the undercoat layer 4
tends to increase.
[0088] Furthermore, when the dispersibility of the metal oxide
particles in the coating liquid for forming an undercoat layer is
improved, the volume resistivity of the undercoat layer 4 tends to
increase. Specifically, by increasing the dispersion treatment time
for the coating liquid for forming an undercoat layer, the volume
resistivity of the undercoat layer 4 tends to increase.
[0089] Intermediate Layer
[0090] An intermediate layer (not shown) may be further provided on
the undercoat layer 4 for improving, for example, the electric
characteristics, the image quality, maintenance of the image
quality, or the adhesiveness of the photosensitive layer. Examples
of the binder resins used for the intermediate layer include
organic metal compounds containing zirconium atoms, titanium atoms,
aluminum atoms, manganese atoms, and silicon atoms, in addition to
polymeric resin compounds, for example, acetal resins such as
polyvinyl butyral, polyvinyl alcohol resins, casein, polyamide
resins, cellulose resins, gelatin, polyurethane resins, polyester
resins, methacrylic resins, acrylic resins, polyvinyl chloride
resins, polyvinyl acetate resins, vinyl chloride-vinyl
acetate-maleic anhydride resins, silicone resins, silicone-alkyd
resins, phenol-formaldehyde resins, and melamine resins.
[0091] The intermediate layer is formed using, for example, a
coating liquid formed by dissolving the binder resin in a solvent.
Examples of the method for coating the coating liquid include known
methods such as a dip coating method, an extrusion coating method,
a wire bar coating method, a spray coating method, a blade coating
method, a knife coating method, and a curtain coating method.
[0092] The thickness of the intermediate layer is set to, for
example, a range of 0.1 .mu.m to 3 .mu.m.
[0093] Charge Generating Layer
[0094] The charge generating layer 5 is configured, for example, to
have charge generating materials dispersed in a binder resin.
[0095] As the charge generating materials, phthalocyanine pigments
such as non-metal phthalocyanine, chlorogallium phthalocyanine,
hydroxygallium phthalocyanine, dichlorotin phthalocyanine,
titanylphthalocyanine, and the like are used, and in particular,
chlorogallium phthalocyanine crystals having strong diffraction
peaks at least at 7.4.degree., 16.6.degree., 25.5.degree., and
28.3.degree. of Bragg angles)(2.theta..+-.0.2.degree. with respect
to CuK.alpha. characteristic X rays, non-metal phthalocyanine
crystals having strong diffraction peaks at least at 7.7',
9.3.degree., 16.9.degree., 17.5.degree., 22.4.degree., and
28.8.degree. of Bragg angles (2.theta.+0.2.degree. with respect to
CuK.alpha. characteristic X rays, hydroxygallium phthalocyanine
crystals having strong diffraction peaks at least at 7.5',
9.9.degree., 12.5.degree., 16.3.degree., 18.6.degree.,
25.1.degree., and 28.3.degree. of Bragg angles
(2.theta..+-.0.2.degree. with respect to CuK.alpha. characteristic
X rays, titanyl phthalocyanine crystals having strong diffraction
peaks at least at 9.6.degree., 24.1.degree., and 27.2.degree. of
Bragg angles (2.theta..+-.0.2.degree. with respect to CuK.alpha.
characteristic X rays and the like are used. In addition, examples
of other charge generating materials include a quinone pigment, a
perylene pigment, an indigo pigment, a bisbenzoimidazole pigment,
an anthrone pigment, a quinacridone pigment, and the like. These
charge generating materials may be used singly or as a mixture of
two or more kinds thereof.
[0096] As the binder resins in the charge generating layer 5, for
example, polycarbonate resins such as a bisphenol A-type resin and
a bisphenol Z-type resin, an acrylic resin, a methacrylic resin, a
polyarylate resin, a polyester resin, a polyvinyl chloride resin, a
polystyrene resin, an acrylonitrile-styrene copolymer resin, an
acrylonitrile-butadiene copolymer, a polyvinyl acetate resin, a
polyvinyl formal resin, a polysulfone resin, a styrene-butadiene
copolymer resin, a vinylidene chloride-acrylonitrile copolymer
resin, a vinyl chloride-vinyl acetate copolymer resin, a vinyl
chloride-vinyl acetate-maleic anhydride resin, a silicone resin, a
phenol-formaldehyde resin, a polyacrylamide resin, a polyamide
resin, or a poly-N-vinylcarbazole resin are used. These binder
resins may be used singly or as a mixture of two or more kinds
thereof.
[0097] The blending ratio (weight ratio) of the charge generating
material and the binder resin depends on the materials to be used,
but is preferably, for example, in the range of 10:1 to 1:10.
[0098] When the charge generating layer 5 is formed, a coating
liquid obtained by adding the above-described components to a
solvent is used.
[0099] In order to disperse the charge generating materials in the
binder resin, the coating liquid is subjected to dispersion
treatment. Examples of the dispersing unit to be used include media
dispersers such as a ball mill, a vibration ball mill, an attritor,
and a sand mill, and medialess dispersers such as a stirrer, an
ultrasonic disperser, a roll mill, and a high-pressure homogenizer.
Further, examples of the high-pressure homogenizer include a
collision-type homogenizer in which a dispersion is dispersed by
liquid-liquid collision, and a liquid-wall collision under high
pressure, and a passing-through-type homogenizer in which a
dispersion is dispersed by passing the dispersion through thin flow
paths under high pressure.
[0100] Examples of the method for coating the coating liquid for
forming a charge generating layer thus obtained on the undercoat
layer 4 include a dip coating method, an extrusion coating method,
a wire bar coating method, a spray coating method, a blade coating
method, a knife coating method, and a curtain coating method.
[0101] The film thickness of the charge generating layer 5 is
preferably set to the range of 0.01 .mu.m to 5 .mu.m.
[0102] Charge Transporting Layer
[0103] The charge transporting layer 6 is configured to have, for
example, charge transporting materials dispersed in a binder
resin.
[0104] Examples of the charge transporting materials include hole
transporting materials such as oxadiazole derivatives such as
2,5-bis(p-diethylaminophenyl)-1,3,4-oxadiazole, pyrazoline
derivatives such as 1,3,5-triphenylpyrazoline and
[0105]
1-[pyridyl-(2)]-3-(p-diethylamino-styryl)-5-(p-diethylaminostyryl)p-
yrazoline, aromatic tertiary amino compounds such as
triphenylamine, N,N'-bis(3,4-dimethylphenyl)-biphenyl-4-amine,
tri(p-methylphenyl)aminyl-4-amine, and dibenzylaniline, aromatic
tertiary diamino compounds such as
N,N'-bis(3-methylphenyl)-N,N'-diphenylbenzidine,
N,N'-diphenyl-N,N'-bis(3-methylphenyl)-[1,1']biphenyl-4,4'-diamine,
1,2,4-triazine derivatives such as
3-(4'-diethylaminophenyl)-5,6-di-(4'-methoxyphenyl)-1,2,4-triazine,
hydrazone derivatives such as
4-diethylaminobenzaldehyde-1,1-diphenylhydrazone, quinazoline
derivatives such as 2-phenyl-4-styryl-quinazoline, benzofuran
derivatives such as 6-hydroxy-2,3-di(p-methoxyphenyl)benzofuran,
.alpha.-stilbene derivatives such as
p-(2,2-diphenylvinyl)-N-N-diphenylaniline, enamine derivatives,
carbazole derivatives such as N-ethylcarbazole, and
poly-N-vinylcarbazole and derivatives thereof, electron
transporting materials such as quinone-based compounds such as
chloranil and broanthraquinone, tetracyanoquinodimethane-based
compounds, fluorenone compounds such as 2,4,7-trinitrofluorenone
and 2,4,5,7-tetranitro-9-fluorenone, a xanthone-based compound and
a thiophene-based compound, and polymers having a group formed of
the above compounds in the main chain or side chain thereof. These
charge transporting materials may be used singly or in combination
of two or more kinds thereof.
[0106] Examples of the binder resin in the charge transporting
layer 6 include insulating resins such as biphenyl copolymerization
type polycarbonate resins, polycarbonate resins such as a bisphenol
A-type resin and a bisphenol Z-type resin, an acrylic resin, a
methacrylic resin, a polyarylate resin, a polyester resin, a
polyvinyl chloride resin, a polystyrene resin, an
acrylonitrile-styrene copolymer resin, an acrylonitrile-butadiene
copolymer resin, a polyvinyl acetate resin, a polyvinyl formal
resin, a polysulfone resin, a styrene-butadiene copolymer resin, a
vinylidene chloride-acrylonitrile copolymer resin, a vinyl
chloride-vinyl acetate-maleic anhydride resin, a silicone resin, a
phenol-formaldehyde resin, a polyacrylamide resin, a polyamide
resin, and chlorinated rubber, and organic photoconductive polymers
such as polyvinylcarbazole, polyvinylanthracene, and
polyvinylpyrene. These binder resins may be used singly or as a
mixture of two or more kinds thereof.
[0107] Furthermore, when the charge transporting layer 6 is the
surface layer of the electrophotographic photoreceptor (layer
disposed farthest from the conductive support 2 of the
photosensitive layer), lubricating particles (for example,
fluorine-based resin particles and silicone-based resin particles
such as silica particles, alumina particles, and
polytetrafluoroethylene (PTFE)) may be incorporated into the charge
transporting layer 6. These lubricating particles may be contained
as a mixture of two or more kinds thereof.
[0108] Further, when the charge transporting layer 6 is the surface
layer of the electrophotographic photoreceptor, fluorine-modified
silicone oil may be added to the charge transporting layer 6.
Examples of the fluorine-modified silicone oil include compounds
having fluoroalkyl groups.
[0109] Further, the weight ratio of the charge transporting
materials and the binder resin in the charge transporting layer 6
may be, for example, in the range of 10:1 to 1:5. That is, the
content of the charge transporting materials with respect to the
total amount of the charge transporting layer 6 may be, for
example, in the range of 17% by weight to 91% by weight.
[0110] The charge transporting layer 6 is formed using a coating
liquid for forming a charge transporting layer obtained by adding
the above-described components to a solvent.
[0111] Examples of the solvent include known organic solvents, for
example, aromatic hydrocarbon-based solvents such as toluene and
chlorobenzene, aliphatic alcohol-based solvents such as methanol,
ethanol, n-propanol, iso-propanol, and n-butanol, ketone-based
solvents such as acetone, cyclohexanone, and 2-butanone,
halogenated aliphatic hydrocarbon solvents such as methylene
chloride, chloroform, and ethylene chloride, cyclic or linear
ether-based solvents such as tetrahydrofuran, dioxane, ethylene
glycol, and diethyl ether, and ester-based solvents such as methyl
acetate, ethyl acetate, and n-butyl acetate. Further, these
solvents may be used singly or in combination of two or more kinds
thereof, and the solvents that are mixed and used are not
particularly limited as long as they are solvents for dissolving
the binder resin as a mixed solvent.
[0112] Examples of the method for dispersing lubricating particles
in the coating liquid for forming a charge transporting layer
include methods using media dispersers such as a ball mill, a
vibration ball mill, an attritor, and a sand mill, or medialess
dispersers such as a stirrer, an ultrasonic disperser, a roll mill,
a high-pressure homogenizer, and nanomizer. Further, examples of
the high-pressure homogenizer include a collision-type homogenizer
in which a dispersion is dispersed by liquid-liquid collision, and
a liquid-wall collision under high pressure, and a
passing-through-type homogenizer in which a dispersion is dispersed
by passing the dispersion through thin flow paths under high
pressure.
[0113] Examples of the method for forming the charge transporting
layer 6 include a method in which the coating liquid for forming a
charge transporting layer is coated and dried on the charge
generating layer 5 of the conductive support 2, in which the
undercoat layer 4 and the charge generating layer 5 are formed,
thereby forming the charge generating layer 6.
[0114] Examples of the method for coating the coating liquid for
forming a charge transporting layer on the charge generating layer
5 include a dip coating method, an extrusion coating method, a wire
bar coating method, a spray coating method, a blade coating method,
a knife coating method, and a curtain coating method.
[0115] Further, after coating the coating liquid on the charge
generating layer 5, heating and drying are carried out to remove
the solvent in the coating liquid. The film thickness of the charge
transporting layer 6 may be, for example, in the range of 5 .mu.m
to 50 .mu.m.
[0116] In order to prevent deterioration of the photoreceptor due
to ozone or nitrogen oxide generated in the image forming
apparatus, or light and heat, additives such as an antioxidant, a
light stabilizer, and a heat stabilizer may be added to the
respective layers constituting the photosensitive layer 3. Examples
of the antioxidant include hindered phenol, hindered amine,
paraphenylenediamine, arylalkane, hydroquinone, spirochromane,
spiroindanone, derivatives thereof, an organic sulfur compound, and
an organic phosphor compound. Examples of the light stabilizer
include derivatives of benzophenone, benzazole, dithiocarbamate,
and tetramethylpiperidine.
[0117] Further, the electrophotographic photoreceptor 1 according
to the present exemplary embodiment may be configured such that the
charge transporting layer 6 is an outermost layer, but a protective
layer may be further formed on the charge transporting layer.
[0118] Image Forming Apparatus
[0119] Next, the image forming apparatus including the
electrophotographic photoreceptor according to the present
exemplary embodiment will be described.
First Exemplary Embodiment
[0120] FIG. 2 schematically shows a basic configuration of the
image forming apparatus of the first exemplary embodiment.
[0121] The image forming apparatus 200 shown in FIG. 2 includes,
for example, the electrophotographic photoreceptor 1 of the
exemplary embodiment; a charging device 208 (charging unit) in a
contact charging mode, that is connected to a power source 209 to
charge the electrophotographic photoreceptor 1; an exposure device
210 (electrostatic latent image forming unit) that exposes the
electrophotographic photoreceptor 1 charged by the charging device
208 to form an electrostatic latent image; a developing device 211
(developing unit) that develops the electrostatic latent image
formed by the exposure device 210 by a developer containing a toner
to form a toner image; a transfer device 212 (transfer unit) that
transfers the toner image formed on the surface of the
electrophotographic photoreceptor 1 onto a transfer medium 500; a
toner removing device 213 (toner removing unit) that removes the
toner remaining on the surface of the electrophotographic
photoreceptor 1 after the transfer; and a fixing device 215 (fixing
unit) that fixes the toner image transferred onto the transfer
medium 500 in the transfer medium 500.
[0122] Furthermore, the image forming apparatus 200 shown in FIG. 3
is an image forming apparatus in an erase-less mode, not including
an erasing unit that removes the charges remaining on the surface
of an electrophotographic photoreceptor after the toner image on
the surface of the electrophotographic photoreceptor is
transferred.
[0123] The charging device 208 has a charging member, and when the
photoreceptor 1 is charged, voltage is applied to the charging
member. As for the voltage range, only DC voltage is applied in the
present exemplary embodiment, and accordingly, the voltage may be
applied in a mode for applying a DC voltage in the range of
positive or negative values from 50 V to 2000 V (preferably from
200 V to 1000 V, and more preferably from 300 V to 700 V), varying
depending on the required charging potential of the
electrophotographic photoreceptor 1.
[0124] Examples of the charging member include a roller, a brush,
and a film. Among these, examples of the roller-shaped charging
member (which may be hereinbelow referred to a "charging roller" in
some cases) include ones constituted with materials having an
electric resistivity adjusted to a range of 10.sup.3.OMEGA. to
10.sup.8.OMEGA.. Further, the charging roller may be constituted
with single layer or plural layers.
[0125] When the charging roller is used as the charging member, the
pressure applied to the photoreceptor 1 may be, for example, in the
range of 250 mgf to 600 mgf.
[0126] Examples of the materials constituting the charging member
include ones having synthetic rubber such as urethane rubber,
silicone rubber, fluorine rubber, chloroprene rubber, butadiene
rubber, EPDM (ethylene-propylene-diene copolymerization rubber),
and epichlorohydrin rubber or elastomers constituted with
polyolefin, polystyrene, vinyl chloride or the like, as major
materials and also having conductivity imparting agents such as
conductive carbon, metal oxide, and an ion conducting agent blended
therein in the appropriate amounts.
[0127] In addition, a paint may be formed by using a resin such as
nylon, polyester, polystyrene, polyurethane, and silicone, and a
conductivity imparting agent such as conductive carbon, metal
oxide, and an ion conducting agent may be blended in appropriate
amounts therewith, and then the obtained paint may be used by
laminating with a dipping method, a spraying method, a roll-coating
method or the like.
[0128] In the case where the charging roll is used as the charging
member, by bringing the charging roll into contact with the surface
of the photoreceptor 1, the charging unit rotates in accordance
with the photoreceptor 1 even when the charging unit does not
include a driving unit, but may rotate at a peripheral speed
different from that of the photoreceptor 1 by mounting a driving
unit in the charging roll.
[0129] As the exposure device 210, a known exposure unit is used.
Specifically, for example, an apparatus in an optical system for
exposure through a light source such as a semiconductor laser, LED
(Light Emitting Diode), and a liquid crystal shutter is used. The
light amount during writing may be, for example, in the range of
0.5 mJ/m.sup.2 to 5.0 mJ/m.sup.2 on the surface of the
photoreceptor.
[0130] Examples of the developing device 211 include a developing
unit in a two-component developing mode, in which a developing
brush (developer holding member) to which a developer containing a
carrier and a toner is attached is brought into contact with an
electrostatic latent image holding member to perform the
development; and a developing unit in a contact-type
single-component developing mode, in which a toner is attached onto
a conductive rubber elastomer transporting roll (developer holding
member) to develop the toner in the electrostatic latent image
holding member.
[0131] The toner is not particularly limited as long as it is a
known toner. Specifically, it may be, for example, a toner
containing at least a binder resin, and if necessary, a colorant, a
release agent or the like.
[0132] The method for preparing a toner is not particularly
limited, but examples thereof include a method for preparing a
toner, using an ordinary pulverization method, a wet-melting
globularization method for preparation in a dispersion medium, and
a polymerization method such as suspension polymerization,
dispersion polymerization, and an emulsion polymerization
aggregation method in the related art.
[0133] When the developer is a two-component developer containing a
toner and a carrier, the carrier is not particularly limited, and
examples thereof include carriers including only core materials,
for example, magnetic metals such as iron oxide, nickel, and
cobalt, and magnetic oxides such as ferrite and magnetite (uncoated
carriers); and resin-coated carriers which have a resin layer
provided on the surface of these core materials. The mixing ratio
(weight ratio) of the toner to the carrier (toner:carrier) in the
two-component developer may be in the range of 1:100 to 30:100 or
may be in the range of 3:100 to 20:100.
[0134] Examples of the transfer device 212 include, in addition to
roller-shaped contact type charging members, a contact type
transfer charger using, for example, a belt, film, or a rubber
blade, or a scorotron transfer charger or corotron transfer charger
using corona discharge.
[0135] The toner removing device 213 is used to remove the
remaining toner attached on the surface the electrophotographic
photoreceptor 1 after the transfer, whereby the electrophotographic
photoreceptor 1 having the cleaned surface is provided by carrying
out the image forming process repeatedly. For the toner removing
device 213, for example, brush cleaning or roll cleaning is used,
in addition to a foreign matter-removing member (cleaning blade),
but among these, a cleaning blade is preferably used. Further,
examples of the material for the cleaning blade include urethane
rubber, neoprene rubber, and silicone rubber.
[0136] Furthermore, in the case where there is no problem with the
remaining toner, for example, in the case where the toner does not
easily remain on the surface of the photoreceptor 1, it is not
necessary to provide the toner removing device 213.
[0137] A basic process of the image forming apparatus 200 for
setting the image will be described.
[0138] First, the charging device 208 charges the surface of the
photoreceptor 1 to a predetermined potential. Next, the surface of
the charged photoreceptor 1 is exposed by an exposure device 210,
based on the image signal, to form an electrostatic latent
image.
[0139] Then, the developer is held on the developer holding member
of the developing device 211, the held developer is transported to
the photoreceptor 1, and fed to the electrostatic latent image at a
position where the developer holding member and the photoreceptor 1
are close to each other (or in contact with each other).
Consequently, the electrostatic latent image is visualized to
become a toner image.
[0140] The developed toner image is transported to the position of
the transfer device 212, and directly transferred to the transfer
medium 500 by the transfer device 212.
[0141] Then, the transfer medium 500 to which the toner image is
transferred is transported to a fixing device 215, and the toner
image is fixed on the transfer medium 500 by the fixing device 215.
The fixing temperature may be, for example, from 100.degree. C. to
180.degree. C.
[0142] On the other hand, after the toner image is transferred to
the transfer medium 500, the toner particles that are not
transferred and remain on the photoreceptor 1 are moved to the
position in contact with the toner removing device 213, and
recovered by the toner removing device 213.
[0143] Consequently, an image is formed by the image forming
apparatus 200.
[0144] Process Cartridge
[0145] FIG. 3 schematically shows a basic configuration of an
example of the process cartridge according to the present exemplary
embodiment. This process cartridge 300 is integrated by combining
an electrophotographic photoreceptor 1; a charging device 208 in a
contact charging mode, that charges the electrophotographic
photoreceptor 1; a developing device 211 that develops the
electrostatic latent image formed on the electrophotographic
photoreceptor 1 by the exposure using a developer containing a
toner to form a toner image; a toner removing device 213 that
removes the toner remaining on the surface of the
electrophotographic photoreceptor 1 after the transfer; and an
opening for exposure 218 using an attachment rail 216.
[0146] Moreover, this process cartridge 300 is configured to be
attachable to or detachable from the main member of an image
forming apparatus including a transfer device 212 that transfers
the toner image formed on the surface of the electrophotographic
photoreceptor 1 onto the transfer medium 500; a fixing device 215
that fixes the toner image transferred onto the transfer medium 500
on the transfer medium 500; and other components not shown, and the
process cartridge 300 constitutes the image forming apparatus
together with the main member of the image forming apparatus.
[0147] The process cartridge 300 may include an exposure device
(not shown) that exposes the surface of the electrophotographic
photoreceptor 1, in addition to the electrophotographic
photoreceptor 1, the charging device 208, the developing device
211, the toner removing device 213, and the opening for exposure
218.
[0148] In addition, the process cartridge according to the present
exemplary embodiment may include at least the electrophotographic
photoreceptor 1 and the charging device 208.
EXAMPLES
[0149] Hereinbelow, the invention will be described in detail with
reference to Examples, but is not construed to be limited to
Examples. Further, "%" is based on weight unless otherwise
specified.
Preparation of Electrophotographic Photoreceptor
Example 1
Preparation of Photoreceptor
[0150] 100 parts by weight of zinc oxide (average particle
diameter: 70 nm, manufactured by Tayca Corporation, and specific
surface area: 15 m.sup.2/g) is mixed with 500 parts by weight of
methanol under stirring. 1.0 part by weight of KBM603
(N-2-(aminoethyl)-3-aminopropyltrimethoxysilane, manufactured by
Shin-Etsu Chemical Co., Ltd.) as a silane coupling agent is added
thereto, followed by stirring for 2 hours. Thereafter, methanol is
evaporated by distillation under reduced pressure, and printing is
carried out at 120.degree. C. for 3 hours to obtain zinc oxide
particles that have been surface-treated with a silane coupling
agent.
[0151] 100 parts by weight of the surface-treated zinc oxide
particles as the metal oxide particles, 1 part by weight of
alizarin as an electron accepting compound having an anthraquinone
structure, 22.5 parts by weight of blocked isocyanate (SUMIDULE BL
3175, manufactured by Sumitomo Bayer Urethane Company Ltd.) as a
curing agent, and 25 parts by weight of a butyral resin (S-Lec
BM-1, manufactured by Sekisui Chemical Co, Ltd.) are dissolved in
142 parts by weight of methyl ethyl ketone to give a solution. 38
parts by weight of this solution is mixed with 25 parts by weight
of methyl ethyl ketone, and the mixture is dispersed in a sand mill
using glass beads having a diameter of 2 mm for 30 hours to give a
dispersion. 0.005 parts by weight of dioctyl tin dilaurate as a
catalyst and 4.0 parts by weight of silicone resin particles
(TOSPEARL 130, manufactured by GE Toshiba Silicones Co., Ltd.) are
added to the obtained dispersion to give a coating solution for an
undercoat layer. The coating liquid is applied on an aluminum
substrate having a diameter of 30 mm by a dip coating method, and
dried at 170.degree. C. for 25 minutes to obtain an undercoat layer
having a thickness of 25 .mu.m.
[0152] Next, a mixture of 15 parts by weight of chlorogallium
phthalocyanine crystals having strong diffraction peaks at least at
7.4.degree., 16.6.degree., 25.5.degree., and 28.3.degree. of Bragg
angles (2.theta..+-.0.2.degree. with respect to CuK.alpha.
characteristic X rays as a charge generating material, 10 parts by
weight of a vinyl chloride-vinyl acetate copolymer resin (VMCH,
manufactured by Nippon Unicar Company Limited), and 300 parts by
weight of n-butyl alcohol is dispersed in a sand mill for 4 hours
using glass beads having a diameter of 1 mm to obtain a coating
liquid for a charge generating layer. The coating liquid for a
charge generating layer is dip-coated on the above-described
undercoat layer, and dried to obtain a charge generating layer
having a thickness of 0.2 .mu.m.
[0153] Next, 4 parts by weight of
N,N'-diphenyl-N,N'-bis(3-methylphenyl)-[1,1']biphenyl-4,4'-diamine
as a charge transporting material, 6 parts by weight of a bisphenol
Z-type polycarbonate resin (viscosity average molecular weight:
40,000) as a binder resin, and 1 part by weight of
2,6-di-t-butyl-4-methylphenol as an antioxidant are mixed, and 24
parts by weight of tetrahydrofuran and 11 parts by weight of
toluene are mixed therewith and dissolved therein. Then, 10 ppm of
fluorine-modified silicone oil (trade name: FL-100, manufactured by
Shin-Etsu Chemical Co., Ltd.) is added thereto, and the mixture is
sufficiently stirred to obtain a coating liquid for forming a
charge transporting layer.
[0154] This coating liquid is coated on the charge generating
layer, and dried at 140.degree. C. for 25 minutes to form a charge
transporting layer having a film thickness of 25 .mu.m, thereby
obtaining a desired electrophotographic photoreceptor.
[0155] The electrophotographic photoreceptor thus obtained is taken
as the photoreceptor 1.
[0156] Measurement of Volume Resistivity of Undercoat Layer
[0157] Preparation of Measurement Sample
[0158] The coating liquid for an undercoat layer used in the
preparation of the photoreceptors of Examples and Comparative
Examples is coated on an aluminum plate by a blade coating method,
and dried and cured at 170.degree. C. for 24 minutes. With respect
to the single-layer film of the undercoat layer, a gold electrode
having a dimension of 100 nm is mounted as an opposite electrode by
a vacuum deposition method and used for measurement of
resistivity.
[0159] Measurement Method
[0160] For the measurement of impedance, an S11287 electrochemical
interface (manufactured by TOYO Corporation) is used as a power
source, an S11260 impedance/gain phase analyzer (manufactured by
TOYO Corporation) is used as an ammeter, and a 1296 dielectric
interface (manufactured by TOYO Corporation) is used as a current
amplifier.
[0161] In a sample for impedance measurement, an aluminum pipe is
used as a cathode and a gold electrode is used as an anode, an AC
voltage with 1 Vp-p is applied from the high-frequency side in the
frequency range of 1 MHz to 1 mHz, and the AC impedance of each
sample is measured at room temperature (22.degree. C., 55% RH) By
fitting a graph with the Cole-Cole plot obtained in the measurement
to the equivalent circuit of parallel RC, the volume resistivity is
obtained. The volume resistivity is shown in Table 1.
[0162] Surface Potential Difference between Exposure Portion and
Non-Exposure Portion
[0163] The electrophotographic photoreceptor 1 is mounted on a
modified device obtained by removing an erasing unit from DocuPrint
C2110 "device configured to carryout direct transfer from the
electrophotographic photoreceptor to paper by applying DC voltage
-600 V to a charging roll to charge an electrophotographic
photoreceptor in a contact charging mode, and applying a voltage of
1500 V to 2000 V to a transfer roll", and charging, exposure (upper
half of the electrophotographic photoreceptor), and transfer are
carried out once each sequentially. Then, when charging and
exposure (front surface) are carried out the surface potential of
the upper half of the electrophotographic photoreceptor (having an
exposure history in the previous cycle) and the lower half of the
electrophotographic photoreceptor (having no exposure history in
the previous cycle) are measured using the electrostatic voltmeter
Trek 334 (manufactured by TREK JAPAN Co., Ltd.), and the difference
in the surface potential is defined as a surface potential
difference .DELTA.Vh at the exposure portion and the non-exposure
portion. The results are shown in Table 1.
[0164] The evaluation criteria are as follows. Further, Paper C2
manufactured by Fuji Xerox is used as paper.
[0165] The evaluation criteria are as follows.
[0166] A: Density unevenness is not generated.
[0167] B: Slight density unevenness is generated at an acceptable
level.
[0168] C: Density unevenness is generated at a poor level with no
edge in the light part.
[0169] D: Density unevenness is generated at a poor level with an
edge noticeable in the concentrated and light parts.
[0170] Image Density Unevenness
[0171] Using the above-described DocuPrint 02110 modified device,
charging, exposure, and transfer are carried out sequentially in
the same manner to print an image shown in FIG. 4 (solid image
(image density 100%) and a halftone image (image density 30%) and
to evaluate the density unevenness of the halftone part shown in
FIG. 4. The results are shown in Table 1.
Example 2
[0172] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 3 parts by weight and the
temperature for drying the undercoat layer is changed to
185.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Example 3
[0173] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 3 parts by weight and the
temperature for drying the undercoat layer is changed to
180.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Example 4
[0174] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 3 parts by weight and the
temperature for drying the undercoat layer is changed to
175.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Example 5
[0175] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 5 parts by weight and the
temperature for drying the undercoat layer is changed to
180.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Example 6
[0176] In the same manner as in Example 1 except that 1 part by
weight of quinizarin is added instead of alizarin, a photoreceptor
is prepared and evaluated in the same manner.
Example 7
[0177] In the same manner as in Example 3 except that 3 parts by
weight of quinizarin is added instead of alizarin, a photoreceptor
is prepared and evaluated in the same manner.
Comparative Example 1
[0178] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 0.5 parts by weight, a
photoreceptor is prepared and evaluated in the same manner.
Comparative Example 2
[0179] In the same manner as in Example 1 except that alizarin is
not added, a photoreceptor is prepared and evaluated in the same
manner.
Comparative Example 3
[0180] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 6 parts by weight and the
temperature for drying the undercoat layer is changed to
190.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Comparative Example 4
[0181] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 6 parts by weight and the
temperature for drying the undercoat layer is changed to
185.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Comparative Example 5
[0182] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 6 parts by weight and the
temperature for drying the undercoat layer is changed to
175.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Comparative Example 6
[0183] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 3 parts by weight and the
temperature for drying the undercoat layer is changed to
185.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
Comparative Example 7
[0184] In the same manner as in Example 1 except that the addition
amount of alizarin is changed to 3 parts by weight and the
temperature for drying the undercoat layer is changed to
165.degree. C., a photoreceptor is prepared and evaluated in the
same manner.
[0185] The results of the respective Examples are shown in Table
1.
TABLE-US-00001 TABLE 1 Undercoat layer of electrophotographic
photoreceptor Electron accepting compound Evaluation Parts by
weight with respect Volume Surface potential difference to 100
parts by weight of metal resistivity between exposure portion and
Density Kind oxide particles (.OMEGA.m) non-exposure portion
.DELTA.Vh (V) unevenness Ex. 1 Alizarin 1 1.0 .times. 10.sup.9 17 B
Ex. 2 Alizarin 3 3.5 .times. 10.sup.8 15 B Ex. 3 Alizarin 3 5.5
.times. 10.sup.8 10 A Ex. 4 Alizarin 3 1.0 .times. 10.sup.9 15 B
Ex. 5 Alizarin 5 5.5 .times. 10.sup.8 14 B Ex. 6 Quinizarin 1 3.8
.times. 10.sup.8 16 B Ex. 7 Quinizarin 3 8.8 .times. 10.sup.8 7 A
Comp. Ex. 1 Alizarin 0.5 5.0 .times. 10.sup.7 20 C Comp. Ex. 2
Alizarin 0 2.5 .times. 10.sup.7 30 D Comp. Ex. 3 Alizarin 6 1.2
.times. 10.sup.8 27 D Comp. Ex. 4 Alizarin 6 5.0 .times. 10.sup.8
22 C Comp. Ex. 5 Alizarin 6 3.0 .times. 10.sup.9 35 D Comp. Ex. 6
Alizarin 3 2.0 .times. 10.sup.8 33 D Comp. Ex. 7 Alizarin 3 4.5
.times. 10.sup.9 32 D
[0186] From the above-described results, it may be seen that in the
present Examples, favorable results from the evaluation of the
surface potential difference and the density unevenness of the
exposure and the non-exposure portion are obtained, as compared
with Comparative Examples.
[0187] The foregoing description of the exemplary embodiments of
the present invention has been provided for the purposes of
illustration and description. It is not intended to be exhaustive
or to limit the invention to the precise forms disclosed.
Obviously, many modifications and variations will be apparent to
practitioners skilled in the art. The embodiments were chosen and
described in order to best explain the principles of the invention
and its practical applications, thereby enabling others skilled in
the art to understand the invention for various embodiments and
with the various modifications as are suited to the particular use
contemplated. It is intended that the scope of the invention be
defined by the following claims and their equivalents.
* * * * *